Connector carry block and connectors



Nov' 16 1965 J. D. ANDERSON ETAL 3,217,872

CONNECTOR CARRY BLOCK AND CONNECTORS Original Filed Nov. 24. 1958 2Sheets-Sheet 1 q Y* 7 INVENToRs M74 L: 7L 5 James D Anderson 7 55 ErnesL. Cheh 9 @in 7! BY 67 i ATTORNEY NOV 16, 1965 1. D. ANDERsoN ETAL3,217,872

CONNECTOR CARRY BLOCK AND CONNECTORS INVENToRs James D Anderson BYErnest L. Cheih ATTORNEY United States Patent O 3,217,872 CONNECTORCARRY BLSK AND CNNECTRS James D. Anderson and Ernest L. Cheb, Norwalk,Conn., znssignors to Burndy Corporation, a corporation of New orkOriginal application Nov. 24, 1958, Ser. No. 775,815, now Patent No.3,021,738, dated Feb. 2t), 1962. Divided and this application Aug. 23,1961, Ser. No. 133,450

2 Claims. (Cl. 206-65) This application is a division of S.N. 775,815filed Nov. 24, 1958, now U.S. Patent 3,021,738, issued February 20,1962.

Our invention relates to a power operated compressing tool, and moreparticular, to a iluid powered tool useful for compressing articles fedto the tool from a magazine.

Previously, tools for crimping small size electrical connectorsconsisted mainly of hand operated mechanical tools requiring theoperator to exert suiiicient manual force to produce the indentation.This operation becomes strenuous and tiresome after a number ofindentations have been made. For large size indentations, hydraulictools have been devised to provide the necessary pressure to make theindentation, but these tools have great bulk and, therefore, are notsuitable for use in tight quarters. Pneumatic tools have also beendevised; however, these consisted of a stationary jaw and a movablerocker type jaw which moved about a fulcrum pin. This type of toolrequires great bulk on the jaws to prevent the tool jaws from springingexcessively and breaking off.

Moreover, while it is known to have a compressing tool capable offeeding a plurality of connectors to the jaws in sequence, it has alwaysbeen considered necessary to couple these connectors together or to feedthem to the jaws through a hopper mechanism.

It is, therefore, an object of our invention to provide a small powercompressing tool which is compact and which can easily be operatedwithout fatigue and which also will produce automatically a full depthof crimp or indent.

Other objects are: to provide such a tool which will lend itself tomagazine feeding; and to provide a magazine feed which is especiallyuseful for positioning electrical connectors in a tool.

Further objects of our invention consist in providing an adjustment totake up for the allowable tolerances in manufacture of the dies used tomake the indentations and other parts of the tools, and a lockingmechanism for this adjustment; to provide an adjustment for the fullcycling control system for the various air pressures at which the toolmay be operated; and to provide a means to enable the force inducing thecam and piston to travel upwards, without jamming the piston, whenmanufacturing tolerances allow the cam to tilt.

Still further objects of our invention consist in providing a magazinefeed which utilizes the connectors positioned in a carry block; a toolwhich utilizes the connectors themselves as a guide for locating anduses spring loaded indenter dies to enclose the circumference of theconnector before indenting.

One of the features of our invention is the provision of a iluidoperated tool for compressing articles in which a pair of dies aremounted on a frame and a piston causes the dies to move in a linear pathtowards each other.

Another feature of our invention is the provision of a tool forcompressing an article between a pair of jaws, in which a carry block isutilized to support a plurality 3,217,872 Patented Nov. 16, 1965 ICC ofarticles and the block is advanced toward the jaws until one of saidarticles contacts a stop, conducive of the proper locating of thatarticle for compressing.

We accomplish these and other objects and obtain our new results as willbe apparent from the device described in the following specification,particularly pointed out in the claims, and illustrated in theaccompanying drawing, in which:

FIG. 1 is a side elevation partly in section of the tool;

FIG. 2 is a view, partly in section, taken along the lines 2 2 of FIG.1;

FIG. 3 is a front elevation;

FIG. 4 is a perspective view of a carry block used in the magazine feedfor supporting the articles to be compressed;

FIG. 5 is a sectional view taken through the carry block and a supportedelectrical connector to be crimped in the tool;

FIG. 6 is a cross-sectional view of the die set used in the tool; and

FlG. 7 is a View of the die set of FIG. 6 compressing an article locatedtherein.

Referring to FIGS. 1-3 of the drawing, a compressing tool in accordancewith the principles ofl our invention is therein illustrated in theactuated position and is shown to comprise a cylinder body 10 and aframe 11 which is clamped to the cylinder and locked in position by capscrews 12 and 13. Cover 14 encloses the frame 11 and is clamped theretoby screws 15 and 16. Within the cylinder is reciprocally mounted a fluidoperated piston 17 provided with a circular groove to house aconventional packing ring 18, and an integrally formed extension 19substantially square in cross section, having a lateral cam surface 2t),a bearing surface 21 and a clearance surface 22 at the end thereof for apurpose to be described later. The other end of the formed extension 20has a convex semi-spherical shape, which mates into a concavesemi-spherical seat or groove 23 on the piston 17. Special washer 24 andconventional packing ring 25 form a seal for the seated semi-sphericalparts. A longitudinal drilled bore 26 is provided in the extension 19 inwhich is secured by pin 27 one end of a return tension spring 28, theother end of the spring being anchored to retaining bolt 29 threadedinto the bottom of the cylinder.

Crimping head At the other end of the frame` 11 there is provided acrimping head comprising complementary upper and lower crimping dieparts 30 and 31. Upper die part 3) is rotatably mounted to link lever 32at pin 33. The link lever 32 is pivoted to the frame 11 at pin 34 androtatably secured to adjustable link 35 at 36. Lower die part 31 ispinned to a plunger or driven member 37 and 38. The driven member 37 isalso connected by a slotted washer 39 to adjusting link socket 4t)within which adjustable link 35 is threadably mounted. The driven member37 is recessed to receive the link socket 40 and slotted at 42 toreceive the slotted washer 39. The end of the driven member 37terminates in a portion 43 which is driven by a socket mechanism as willbe hereinafter described.

When the plunger is upwardly driven the lower die part 31 and link parts35 an-d 40 are simultaneously moved. The link lever 32, by reversing thelink movement, drives the upper die part 30 towards lower die part 31 ina linear movement. Thus the die parts are compressed towards each otherabout an inserted article. To maintain the various moving parts inposition, the frame 11 is provided with a bore 44 into which the drivenplunger 43 slides. The die parts are confined in the frame, forcing thedie parts to move only in a linear direction towards and away from eachother about the article which is held in a stationary position duringthe crimping operation.

Between the fluid driven piston 17 and the crimping head is the drivingrocker mechanism which comprises the rocker 45 pivotally mounted to theframe 11 at fulcrum pin 46. Provided at one leg of the rocker 45 isroller bearing 47 supported thereto by pin 48, and on the other leg fordriving plunger portion 43 is mounted roller bearing 49 supported on theleg 50 of the rocker by pin 51. Return spring 52 is mounted to the endof the plunger portion 43 by pin 53 and to the frame 11 by pin 54. Thereturn spring 52 thus `forces the plunger portion 43 to the retractedposition, opening die parts 30 and 31 which are always ready to receivea connector in position for crimping. The return spring 52 also causesthe rocker 45 to ride the cam surface 20 on roller 47.

Roller bearings 55 and 56 are mounted within the head of the tool bycross pins 57 and 58, respectively, and ride on bearing surface 21 ofthe piston extension 19 to maintain the piston extension 19 in a properalignment when fully extended for the crimping operation. The camsurface is designed to give the rocker 45 its greatest movement at thestart of the crimping operation and to transmit the greatest forcetoward the end thereof.

The lever handle 59, controlling the power operation of the tool, ispivotally mounted through an ear 60 at one end, to the circular baseportion of the head of the tool by screw 12. The lever handle extendssubstantially the length of the body 10 to the end thereof and isprovided with offset portion 61 at the free end. A small projection 62on the lever handle 59 near the extending ear 60, abuts the circularbase portion 63 of the frame 11 to limit the outward lmovement of thelever handle 59.

Valve unit The valve unit 64 is located at the lower end of the body 10.Two longitudinally drilled uid passages 65 `and 66 lead to the inside ofthe body and offset from the center thereof to avoid interference by theanchoring bolt 29 connected to the return spring 28; exhaust passage 65extends to the atmosphere, while inlet passage 66 extends to the inletport 67, to which is threadedly attached the exible air inlet hose 66.The valve cylinder 69 is transversely positioned in the valve unit tointercept the passages 65 and 66 and receive the valve piston 70 having`an annular undercut groove 71 which contains conventional packing ring72 to prevent leakage from passages 66 to 65. The valve piston 70 isspring loaded by return spring 73 to an extended position to block theinlet passage 66, at which time the exhaust port 65 is open to vent thecylinder around the spring end of the piston. The piston is movedinwardly by the offset portion 61 of the lever handle 59, compressingthe return spring 73 and aligning the stem 74 of the valve piston withthe passage 66 to permit charging the cylinder, and simultaneouslyblocking the exhaust passage 65. At the back end of the valve unitlocated near the return spring, is an adjusting screw '75 which containsa longitudinally drilled hole 76 for release to the atmosphere of anyleaking fluid. At the front end of the valve unit is a valve adaptor 77which is counterbored to receive a conventional packing ring to preventleakage around the stem of the valve piston and is held in place byvalve adaptor cap 78, which is threaded into the front end of the valveunit. Angularly drilled hole 79 allows fluid leakage to escape to thecylinder, allowing the valve piston to operate to its full stroke.

Supporting aperture 80, located at the end of the valve unit, permitsthe tool to be conveniently suspended when not in use.

Magazine The feeding mechanism comprises an auxiliary carry blockcompartment 81 secured to the frame portion 11 by screws 82. Thecompartment stores a plurality of stacked carry blocks 83 and includes aslotted bottom frame 84, end portion 85 suitably secured thereto, cover86 hinged at pin 87 and snap-locked at latch 88. Hinged on the inside ofthe cover at 89 is a skid 90 which is acted upon by spring 91, hinged at92 and 93. Skid 90 urges the carry blocks 83 towards the bottom frame84. A feed trigger 94 is mounted to a bracket 95 and slides in slot 96of the bottom frame 84. A coiled spring 97 is contained in the feedtrigger with one end of the spring secured to the frame. The spring 97is tightened by sliding the feed trigger to the end of the slot/96 inthe bottom frame 84 in the position indicated by the dotdash lines inFIG. l.

The upper portion of the feed trigger may be employed as a carry blockdriver 98. The driver in the retracted position shown in dot-dash linesfalls behind the lowest positioned carry block which is thus urged bythe coiled spring 97 to enter feed slot 99 into the compressing device.

The carry block 83 is shown in FIGS. 4 and 5 comprising a rectangularblock of suitably shape-returning material such as polyethylene or nylonplastic and is provided with a series of spaced bores 100, each borecontaining an article to be compressed, such as the connector 101.

The connector barrel 102 which is to be crimped to the bared end of thewire 103 extends beyond the end of the carry block 83. As the cartridgepasses into slot 99, the sides of the connector barrel 102 areaccommodated within upper and lower grooves 104 and 105 formed in thesides of the upper and lower die parts 30 and 31, respectively.

When the die parts are opened, the cartridge-block 83 holding connectorbarrel 102 in position is advanced by spring 97 into the compressingdevice until the barrel 102 is directly in position for crimping. Atthis point the connector barrel engages a stop 106. This positions theconnector 101 for crimping. Upon insertion of the conductor 103 throughframe opening 107 into the barrel 102, the tool is operated and theconnector is crimped or indented. The crimped connector is pulled out ofthe bore of the carry block and away from stop 106; releasing the carryblock 83 which advances until another protruding connector engages thestop 106 permitting a new connection to be made.

As is shown in FIG. 5, the bore of the carry block 83 imay be providedwith peripherally extending shoulders 108 and 109, one at each end ofthe bore 100 which are formed to cooperate with corresponding shoulders110 and 111 of the connector as shown. Since the block is made of ashape-returning or resilient material, shoulders 103 and 109 areresilient and although deformed on the insertion of the connector 101into the bore 100, will snap back to secure the connector againstaccidental release from the bore.

Other methods may be employed to secure the connectors inside the carryblocks.

It will be readily seen that if a connector is missing from one of thebores, the carry block 83 will advance until next available connectorreaches the stop 106 which automatically positions its connector forproper crimping.

As the completed connections are finally pulled from the carry block,the used carry block is expelled through opening 112 in the frame 11 anda new block 83 falls upon driver 93 urged by spring 91. The new carryblock is then inserted into the crimping device by cocking the feedtrigger 94 as previously explained.

Loading Operation In order to load the compressing tool of our inventionand feed a connector into the crimping position, it is lsupply notshown.

first necessary to release the cover latch 88 and open the cover 86about pin 87, as shown by the dotted lines in FIG. 1. A plurality ofcarry blocks 83 are aligned and fed into the magazine slots 113. Theslots 113 guide the carry blocks into proper alignment. The cover 86 isthen closed and locked in place by cover latch 88. When the cover 86 isclosed, the skid 90, which is spring loaded due to spring 91, will bedeflected and apply a slight pressure on the carry strips 83. The feedtrigger 95 is then retracted to the dotted position 95 shown. Thiscauses the spring loaded skid 90 to force the lowest carry block 83 downinto the feed position. Releasing the feed trigger 95 from its retractedposition causes the driver 98 to push the lowermost carry block 83 intothe slot 99 until the first connector in the carry block abuts againstthe connector stop 106 connected to the lower die half 31. Thecompressing tool is now in position to make a connection between aconductor and connector.

A conductor (from which the insulation, if any, is stripped from theend) is inserted in the connector barrel 102, and the actuating lever 59is pressed and released.

Compressz'ng operation The external air line 68 is coupled to a sourceof air With the conductor 103 positioned in the connector barrel 102,the lever 59 is actuated. This actuation depresses the valve piston 70,closes the air exhaust port 65 and opens the air inlet port 67, allowingair to flow into the cylinder 10. The extension 10, which is coupled tothe piston 17, is caused to move upward due to the pressure building upin the cylinder 10. The upward movement of the extension 19 causes thecam rocker 45 to rotate about pin 46, producing an upward movement ofthe driver member or plunger 37.

This upward movement of the plunger 37 is transmitted in two directions.At the right side of the plunger 37 the movement is transmitted out intoan upward movement of the lower die set 31. At the left side of theplunger 37, the movement is transmitted by adjustable link 35 to pivotthe link lever 32 about pivot pin 34, causing the upper die half 30 tomove downward. As the upper and lower die portions 30 and 31 move towardeach other under the action of the mechanism described above, groovedconfining blocks 114 and 115 close about the connector barrel 102.

As the compression cycle progresses, the confining blocks 114 and 115are further compressed against their springs 116, 117, 118 and 119,causing the indenter pins 120 and 121 to move inward, contacting anddeforming the connector barrel 102 into a uniform controlled compressiongrip about the conductor 103. Releasing the actuating lever 59 allowsthe spring loaded valve piston 70 to close off air inlet port 67 andopen air exhaust port 65. This allows the mechanism to retract to itsopen position. The retraction of piston 17 due to return spring 28permits the movable die parts 30 and 31 to be open and the rockerdepressed by spring 52. This permits the compressed wire and connector103 and 101 to be removed by a pull on the wire. Due to the plasticcharacteristics of carry block 83, the connector is released. Under theaction of the drive 98, the carry block is advanced until the nextconnector in the carry block abuts the stop 106 and enables the cycle tobe repeated.

Full cycling features The full cycle control feature which preventsincornplete compression from occurring if the actuating lever 59 is notdepressed long enough operates as follows:

When the actuating lever 59 is depressed, it opens air passages 66 and67 and blocks the exhaust passage 65. This allows fluid pressure to flowinto the cylinder 10. This liuid pressure produces a force on thesurface of the valve piston 70 which is greater than the returning forceof spring 73. A sealed pressure chamber is thereby produced and theactuating lever 59 can be released without the valve piston 70 returningto its outer or extended position. Therefore, this compels the piston 17and extension 19 to travel to its fully extended position, producing acomplete and full crimp. Upon reaching its fully extended position,conventional packing ring 18 on piston 17 passes the cycling releasehole 122 in the cylinder 10 and relieves the pressure in the sealedchamber which removes the force on the valve piston 70. The valve pistonreturn spring 73 can now push the valve piston back to its originalposition. Through this method, it is impossible to obtain anything lessthan a full and complete crimp. The full cycling control can be adjustedfor various fluid pressures by adjusting screw 75 which in turn adjuststhe tension on spring 73.

Adjustments Adjustment for manufacturing tolerances is obtained asfollows: With the crimping dies in closed position and the actuatingtrigger 59 depressed so that the extension 19 and piston 17 are in theirfully extended position, the lock nut 123 is loosened and adjusting link35 is rotated in its socket 40 until the crimping dies 30 and 31 arefirmly supported. Upon obtaining firm support of the crimping dies 30and 31, the lock nut 123 is then tightened, securing parts 35 and 40 inproper position. This type of adjustment allows for wider manufacturingtolerances.

The free floating action of the cam and piston is obtained in this way:The rounded ball-shaped end is located at the bottom of cam or pistonextension 19 and mates in the spherical seat or groove 23 in piston 17.This allows the piston extension 19 to rotate slightly if necessary inany direction through a small angle. Therefore, if manufacturingtolerances or other factors allow lthe piston extension to tiltslightly, the piston itself will not tilt within the cylinder due to themating spherical ball and spherical groove. The piston, therefore,cannot jam in the cylinder and prevent the tool from functioningproperly. This allows wider manufacturing tolerances to be used.Conventional packing ring 25 prevents leakage around the matingspherical ball and spherical groove.

The novel crimping mechanism permits both upper and lower die parts tobe linearly opened and closed about a connector which may thus slidelaterally into the proper position for crimping in its cartridge blocksupport. The linear movement of the die parts also gives a better crimp.By providing a stop for the transported connector, we are able tocontinue crimping operations even though one or more connectors may havebeen removed from the carry block for various reasons. The samecartridge block may be employed for various sizes and types ofconnectors with corresponding adjustment sometimes required only in thecrimping dies.

We have thus described our invention, but we desire it understood thatit is not confined to the particular form or uses shown and described,the same being merely illustrative and that the invention may be carriedout in other ways without departing from the spirit of our invention andtherefore we claim broadly the right to employ all equivalentinstrumentalities coming within the scope of the claims, and by means Ofwhich objects of our invention are attained and new resultsaccomplished, as it is obvious that the particular embodiments hereinshown and described are only some of the many that can be employed toattain these objects and accomplish these results.

We claim:

1. An assembly of elongated electrical connectors, comprising: anelongated unitary rectangular block having a plurality of spaced apartbores therein the central axis of said bores disposed in a plane; aconnector having a first and second shoulder disposed in each of saidbores; a first axially flexible resilient constriction in said bore tocooperate with one of said connector shoulders to prevent overinsertionof said connector into said bore; a Second axially flexible resilientconstriction spaced from Said first constriction in said bore grippingsaid connector and preventing accidental Withdrawal of said connectorfrom said bore.

2. An assembly of elongated electrical connectors, comprising: anelongated unitary rectangular block, having a plurality of spaced apartbores therein the central axis of said bores disposed in a plane; aconnector disposed in each of said bores; a first axially flexibleconstriction in each said bore to prevent overinsertion of each saidconnector; a radial projection on each said connector; a second axiallyexible resilient constriction spaced from said rst constriction in eachsaid bore adapted to be distorted and passed by said connector radialprojection when each said connector is forcibly inserted into each saidbore and to snap-lock behind said radial projection, 15

thereby preventing accidental Withdrawal of each said connector fromeach said bore.

'8 References Cited by the Examiner UNITED STATES PATENTS 10/ 1938Hopkins 206-52 7/1950 Scholl 206--52 9/1950 Frei et al 339--63 2/ 1958Henning 206-56 12/1960 Chadwick 206-56 2/1961 Simons 206-65 X 8/1961Glazer 206-65 FOREIGN PATENTS 3/ 1954 Great Britain.

THERON E. CONDON, Primary Examiner.

WALTER A. SCHEEL, GEORGE O. RALSTON,

Examiners.

1. AN ASSEMBLY OF ELONGATED ELECTRICAL CONNECTORS, COMPRISING: ANELONGATED UNITARY RECTANGULAR BLOCK HAVING A PLURALITY OF SPACED APARTBORES THEREIN THE CENTRAL AXIS OF SAID BORES DISPOSED IN A PLANE; ACONNECTOR HAVING A FIRST AND SECOND SHOULDER DISPOSED IN EACH OF SAIDBORES; A FIRST AXIALLY FLEXIBLE RESILIENT CONSTRICTION IN SAID BORE TOCOOPERATE WITH ONE OF SAID CONNECTOR SHOULDERS TO PREVENT OVERINSERTIONOF SAID CONNECTOR INTO SAID BORE; A SECOND AXIALLY FLEXIBLE RESILIENTCONSTRICTION SPACED FROM SAID FIRST CONSTRICTION IN SAID BORE GRIPPINGSAID CONNECTOR AND PREVENTING ACCIDENTAL WITHDRAWAL OF SAID CONNECTORFROM SAID BORE.